Oxygen-enhanced combustion

779 Pages·2013·63.317 MB·English

by  Baukal, Charles E

Baukal
Mechanical Engineering
O
OXYGEN-ENHANCED X
Y
COMBUSTION G
E
N
SECOND EDITION
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E
N
Combustion technology has traditionally been dominated by air/fuel combustion. However, two
developments have increased the significance of oxygen-enhanced combustion—new technologies H
that produce oxygen less expensively and the increased importance of environmental regulations.
Advantages of oxygen-enhanced combustion include less pollutant emissions as well as increased energy A
efficiency and productivity. Oxygen-Enhanced Combustion, Second Edition compiles information
N
about using oxygen to enhance industrial heating and melting processes. It integrates fundamental
principles, applications, and equipment design in one volume, making it a unique resource for specialists C
implementing the use of oxygen in combustion systems.
E
This second edition of the bestselling book has more than doubled in size. Extensively updated and D
expanded, it covers significant advances in the technology that have occurred since the publication of
the first edition.
C
What’s New in This Edition O
• Expanded from 11 chapters to 30, with most of the existing chapters revised M
• A broader view of oxygen-enhanced combustion, with more than 50 contributors from over 20
organizations around the world B
• More coverage of fundamentals, including fluid flow, heat transfer, noise, flame impingement,
U
CFD modeling, soot formation, burner design, and burner testing
• New chapters on applications such as flameless combustion, steel reheating, iron production, S
cement production, power generation, fluidized bed combustion, chemicals and petrochemicals, T
and diesel engines
I
O
This book offers a unified, up-to-date look at important commercialized uses of oxygen-enhanced
combustion in a wide range of industries. It brings together the latest knowledge to assist those researching,
N
engineering, and implementing combustion in power plants, engines, and other applications.
SECOND
EDITION
K12887
ISBN: 978-1-4398-6228-5
90000
9 781439 862285
K12887_COVER_final.indd 1 1/9/13 6:35 PM

OXYGEN-ENHANCED
COMBUSTION
SECOND EDITION
IndustrIal combustIon serIes
Series Editors:
Charles E. Baukal, Jr.
The Coen & Hamworthy Combustion Handbook:
Fundamentals for Power, Marine & Industrial Applications
Stephen Londerville and Charles E. Baukal, Jr.
The John Zink Hamworthy Combustion Handbook, Second Edition
Volume 1—Fundamentals
Volume II—Design and Operations
Volume II1—Applications
Charles E. Baukal, Jr.
Industrial Burners Handbook
Charles E. Baukal, Jr.
The John Zink Combustion Handbook
Charles E. Baukal, Jr.
Computational Fluid Dynamics in Industrial Combustion
Charles E. Baukal, Jr., Vladimir Gershtein, and Xianming Jimmy Li
Heat Transfer in Industrial Combustion
Charles E. Baukal, Jr.
Oxygen-Enhanced Combustion
Charles E. Baukal, Jr.
OXYGEN-ENHANCED
COMBUSTION
SECOND EDITION
Edited by
Charles E. Baukal Jr.
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2013 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20130111
International Standard Book Number-13: 978-1-4398-6230-8 (eBook - PDF)
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Contents
List of Figures ..........................................................................................................................................................................vii
List of Tables ........................................................................................................................................................................xxvii
Preface to the First Edition ................................................................................................................................................xxxiii
Preface to the Second Edition ............................................................................................................................................xxxv
Acknowledgments ............................................................................................................................................................xxxvii
Editor....................................................................................................................................................................................xxxix
Contributors ..............................................................................................................................................................................xli
1. Introduction ........................................................................................................................................................................1
Charles E. Baukal, Jr.
2. Fundamentals ...................................................................................................................................................................25
Charles E. Baukal, Jr.
3. Oxygen Production..........................................................................................................................................................43
Roger M. McGuinness and William T. Kleinberg
4. Noncryogenic Oxygen Production ...............................................................................................................................77
Frank George Kerry
5. Potential Hybrid Methods for Oxygen Production ..................................................................................................89
Kyle P. Kostroski and Phillip C. Wankat
6. Safety Overview ............................................................................................................................................................109
Mark A. Niemkiewicz and J. Scott Becker
7. Cleaning for Oxygen Systems ....................................................................................................................................121
Frank George Kerry
8. Fuels ..................................................................................................................................................................................137
Y.-P. Zhang
9. Fluid Flow ........................................................................................................................................................................161
Wes Bussman and Charles E. Baukal, Jr.
10. Heat Transfer ..................................................................................................................................................................197
Charles E. Baukal, Jr.
11. Noise .................................................................................................................................................................................239
Wes Bussman, Jay Karan, Carl-Christian Hantschk, and Edwin Schorer
12. Flame Impingement ......................................................................................................................................................261
Charles E. Baukal, Jr.
13. Pollutant Emissions .......................................................................................................................................................299
Charles E. Baukal, Jr.
14. CFD Modeling of Oxygen-Enhanced Combustion ................................................................................................327
Ananth Sharma and Sreenivas Jayanti
v
vi Contents
15. Soot Formation in Oxygen-Enhanced Combustion ...............................................................................................385
Wilson Merchan-Merchan, Sergio Granados Sanmiguel, Alexei V. Saveliev, and Stephen McCollam
16. Laser Diagnostics for Oxygen-Enhanced Combustion .........................................................................................409
Sameer V. Naik and Robert P. Lucht
17. Equipment Design .........................................................................................................................................................423
Mark A. Niemkiewicz and J. Scott Becker
18. Burner Design ................................................................................................................................................................445
Hisashi (Sho) Kobayashi, Rémi Tsiava, and Charles E. Baukal, Jr.
19. Oxyfuel and Oxygen-Enhanced Burner Testing .....................................................................................................471
Lawrence E. Bool III, Nicolas Docquier, Chendhil Periasamy, and Lee J. Rosen
20. Flameless Oxyfuel Combustion and Its Applications ...........................................................................................495
Wlodzimierz Blasiak, Weihong Yang, Tomas Ekman, and Joachim von Schéele
21. Iron Production ..............................................................................................................................................................517
Michael F. Riley and Thomas Niehoff
22. Ferrous Metals ................................................................................................................................................................531
Nicolas Docquier, Michael Grant, and Kenneth Kaiser
23. Nonferrous Metals ........................................................................................................................................................557
Thomas Niehoff
24. Glass .................................................................................................................................................................................571
Prince B. Eleazer III and Bryan C. Hoke, Jr.
25. Oxygen Combustion in Cement Production ............................................................................................................585
Frank Zeman
26. Thermal Oxidation ........................................................................................................................................................607
Charles E. Baukal, Jr.
27. Coal-Fired Oxy-Fuel Technology for Carbon Capture and Storage ....................................................................631
Terry Wall, Rohan Stanger, and Dennis McDonald
28. Oxy-Fuel Fluidized Bed Combustion ........................................................................................................................649
L. Jia, Luis M. Romeo, Luis I. Díez, Isabel Guedea, Irene Bolea, and Carlos Lupiañez
29. Oxygen Enrichment in Sulfur Recovery ..................................................................................................................675
John A. (Jack) Olesen and Jana Janarthanan
30. Diesel Engines ................................................................................................................................................................681
Theodoros C. Zannis, Yiannis A. Levendis, Dimitrios T. Hountalas, Elias A. Yfantis,
and Roussos G. Papagiannakis
Appendix ................................................................................................................................................................................711
List of Figures
Figure 1.1 S chematic of premixing O with air. ...............................................................................................................3
2
Figure 1.2 S chematic of O lancing. ...................................................................................................................................4
2
Figure 1.3 S chematic of oxy/fuel. .......................................................................................................................................5
Figure 1.4 S chematic of air-oxy/fuel burner. ....................................................................................................................5
Figure 1.5 O xidizer compositions for blends of air and pure O ...................................................................................6
2
Figure 1.6 O xy/fuel + flue gas recycle. ..............................................................................................................................6
Figure 1.7 Flue gas recirculation. .......................................................................................................................................6
Figure 1.8 F urnace gas recirculation..................................................................................................................................6
Figure 1.9 F uel requirement to produce 1 MMBtu = 1 × 106 Btu (HHV) vs. flue gas temperature as a
function of the oxidizer composition and temperature ...............................................................................8
Figure 1.10 E xhaust gases net heat content increase factor for oxy/fuel compared to air/fuel ..................................9
Figure 1.11 N atural gas savings vs. flue gas temperature for oxidizers ranging from air to pure O . ....................16
2
Figure 1.12 F uel savings vs. flue gas temperature as a function for natural gas and No. 6 oil using OEC
compared to air for combustion.....................................................................................................................17
Figure 1.13 F uel savings vs. flue gas temperature as a function of fuel type using oxygen instead of air for
combustion. .......................................................................................................................................................17
Figure 1.14 B reakeven cost curve for the ratio of the cost of O to the cost of fuel (C) vs. the required
2
increase in fuel efficiency (f) for two different ratios of the oxygen to fuel flow rate (F). ....................19
Figure 2.1 C alculated excess O in the oxidizer (consisting of O + N) and in the dry combustion
2 2 2
products as a function of the O in the oxidizer for the combustion of methane with 15% excess
2
oxidizer. .............................................................................................................................................................27
Figure 2.2 E nhanced chemical reactivity of oxy/fuel compared to air/fuel combustion. .........................................28
Figure 2.3 A diabatic equilibrium reaction process. ......................................................................................................29
Figure 2.4 M ajor species concentrations vs. oxidizer composition, for an adiabatic equilibrium
stoichiometric CH flame. ...............................................................................................................................29
4
Figure 2.5 M inor species concentrations vs. oxidizer composition, for an adiabatic equilibrium
stoichiometric CH flame. ...............................................................................................................................29
4
Figure 2.6 E quilibrium predicted gas composition of the major species as a function of the gas
temperature for air/CH and O/CH flames. .............................................................................................30
4 2 4
Figure 2.7 E quilibrium predicted gas composition of the minor species as a function of the gas
temperature for air/CH and O/CH flames...............................................................................................30
4 2 4
Figure 2.8 A diabatic equilibrium predicted gas composition of the major species as a function of the
stoichiometry for air/CH and O/CH flames. ...........................................................................................31
4 2 4
Figure 2.9 A diabatic equilibrium predicted gas composition of the minor species as a function of the
stoichiometry for air/CH and O/CH flames. ...........................................................................................31
4 2 4
Figure 2.10 A diabatic flame temperature vs. oxidizer composition, for an adiabatic equilibrium
stoichiometric CH flame. ...............................................................................................................................32
4
vii
viii List of Figures
Figure 2.11 C alculated burning temperature vs. O in the oxidizer (O + N) for isooctane and kerosene
2 2 2
drops at an initial temperature of 77°F. ........................................................................................................32
Figure 2.12 A diabatic flame temperature vs. stoichiometric for a CH flame and various oxidizers. .....................32
4
Figure 2.13 A diabatic flame temperature vs. oxidizer preheat temperature for stoichiometric air/CH and
4
O/CH flames. .................................................................................................................................................32
2 4
Figure 2.14 ( a) Contour plot of the adiabatic equilibrium flame temperature (°F) vs. oxidizer composition
and O :CH stoichiometry for the combustion of ambient temperature methane. (b) Contour
2 4
plot of the adiabatic equilibrium flame temperature (K) vs. oxidizer composition and O :CH
2 4
stoichiometry for the combustion of ambient temperature methane. .....................................................33
Figure 2.15 Example of a Sankey diagram. ......................................................................................................................34
Figure 2.16 A vailable heat vs. oxidizer composition, for a stoichiometric CH flame, at exhaust
4
temperatures of 2000°F, 2500°F, and 3000°F. ................................................................................................34
Figure 2.17 A vailable heat vs. exhaust gas temperature, for stoichiometric air/CH and O/CH flames. .............35
4 2 4
Figure 2.18 A vailable heat vs. oxidizer preheat temperature, for stoichiometric, equilibrium air/CH and
4
O/CH flames at an exhaust gas temperature of 2500°F (1644 K). ...........................................................35
2 4
Figure 2.19 E xperimentally determined quench distance vs. O in the oxidant (consisting of O + N) for
2 2 2
the stoichiometric combustion of propane measured at two different mixture pressures. ................36
Figure 2.20 U pper and lower flammability limits vs. oxidizer composition, for a CH flame. ................................36
4
Figure 2.21 N ormal flame propagation velocity vs. oxidizer composition, for a stoichiometric CH flame. ........37
4
Figure 2.22 M aximum flame velocity vs. the mole fraction of O in the oxidant (consisting of O + N)
2 2 2
for various fuels, relative to the velocity for an oxidant with 0.21 mol fraction in the oxidant
(approximately air) ..........................................................................................................................................37
Figure 2.23 D etonation velocities of methane-, ethane-, propane- butane-, and hexane-oxygen mixtures at
atmospheric pressure. .....................................................................................................................................38
Figure 2.24 M inimum ignition energy vs. oxidizer composition for an atmospheric pressure,
stoichiometric CH flame ................................................................................................................................38
4
Figure 2.25 I gnition temperature vs. oxidizer composition, for a stoichiometric CH flame. ...................................38
4
Figure 2.26 C alculated gas density for adiabatic equilibrium stoichiometric flames as a function of the
oxidizer (O + N) and fuel compositions. ....................................................................................................39
2 2
Figure 2.27 N ormalized flue gas volume vs. oxidizer composition, for a stoichiometric CH flame. .....................40
4
Figure 2.28 C alculated gas specific heat for adiabatic equilibrium stoichiometric flames as a function of the
oxidizer (O + N) and fuel compositions. .....................................................................................................40
2 2
Figure 2.29 C alculated gas thermal conductivity for adiabatic equilibrium stoichiometric flames as a
function of the oxidizer (O + N) and fuel compositions. .........................................................................41
2 2
Figure 2.30 C alculated gas viscosity for adiabatic equilibrium stoichiometric flames as a function of the
oxidizer (O + N) and fuel compositions. ....................................................................................................41
2 2
Figure 2.31 C alculated Prandtl number for adiabatic equilibrium stoichiometric flames as a function of the
oxidizer (O + N) and fuel compositions. .....................................................................................................42
2 2
Figure 2.32 C alculated Lewis number for adiabatic equilibrium stoichiometric flames as a function of the
oxidizer (O + N) and fuel compositions. .....................................................................................................42
2 2
Figure 3.1 T echnology selection chart. ............................................................................................................................44
Figure 3.2 ASU block diagram. .....................................................................................................................................45
Figure 3.3 S imple PFD of an ASU. ....................................................................................................................................45